3.1 Location
As the majority of system installations vary greatly, only general comments can be made as to location.
Prior to installing the system, it is suggested to make a system layout plan. During the system layout, take
into consideration any potential shading of the solar electric modules, wire runs, wire size, conduit runs,
trenching, controller accessibility, tank location, pump head etc. Shading even a small portion of the array
can reduce the output of the entire array and thus reduce or completely stop the output of the pump. There
is no substitute for a good plan!
The PCC-series controller can either be mounted indoors or outdoors. Locate all system equipment as
close as possible to each other. For top of pole mount racks, the controller is usually mounted on the north
side (shaded side) of the mounting pole. The controller must be mounted in a vertical position for proper
cooling and to keep the electronics dry. The controller should be located close to the pump if possible. This
general physical layout is conducive to clean installation both aesthetically and electrically.
3.2
System Design Basics
(Read carefully before installation)
1.
The pump discharge piping should be sized for efficient pump operation. Pipe size being too
small will create greater friction losses which require more power to operate and thus a higher
solar module cost.
2.
Make sure the pool filter is size correctly for the flow rate of the pump. A filter sized too small
will create higher friction losses and will increase the power requirements and thus the cost of
the system.
3.
For optimum pump performance make sure that the wire is sized properly for the length of run
between the pump and the solar modules as specified by the National Electric Code. Wire sized
too small will cause a decreased output from the pump. Keep the distance from the solar
modules to the pump as short as possible. Refer to a DC wire loss chart for proper sizing. It is
recommended to keep the voltage drop under 3%. Refer to the wire sizing guide on the
SunPumps web site under Engineering.
4.
Never install the controller in direct sunlight. Direct sunlight on the controller may cause over-
heating of the controller.
5.
Never lay the controller on the ground or mount the controller in a horizontal position.
The
controller should be mounted in a vertical position only.
A convenient place to mount the
controller is on the north side (shaded side) of the solar module array.
6.
The controller should be grounded to the pump motor housing, the frame of the solar modules
and to an 8-foot ground rod. Use only a copper lug to attach the ground rod. Always use a DC
surge/lightning arrestor on the panel side of the controller. (Midnight Solar MN-SPD surge
arrestor is recommended)
7.
Do not ground the array positive or negative electrical wires.
3.3 Pump Installation
1.
The pump should be located next to the pool filter. It is highly recommend that you install unions on
both the suction and the discharge ports for easy pump removal for future service.
2.
Write the pump, motor and controller model number and serial number in the space provided on the
last page in this Instruction Manual. This information will be needed when filling out the Warranty Card.
And will aide in any troubleshooting which may be necessary.
3.
Inspect all components for shipping damage and insure that you have all the components that are
required for a complete installation.
4.
Select a well-ventilated, shaded location in which to vertically mount the controller. Mount the
controller far enough from the pool where it could not get wet.
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